Decorative Layer Metallic Appearance via UV Resin Gaps
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Solution Overview
Problem
Achieving a three-dimensional and metallic appearance through ink-jet printing with UV-curable metallic ink is challenging due to viscosity issues, clogging of nozzles, and oxidation of metal flake pigments, making it costly and difficult to achieve the desired effect.
Innovation Solution
A decorative layer is created by layering multiple tuples of UV-curable adhesive and metallic material layers, where the metallic material layers are exposed through gaps in the adhesive layers, allowing for a deep and three-dimensional metallic appearance without using UV-curable metallic ink, thereby reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If UV-curable metallic ink is used for ink-jet printing to achieve three-dimensional and metallic appearance, then the aesthetic effect is improved, but the nozzles are clogged due to viscosity changes and metallic powder accumulation
Solution Approach 1:
The patent divides the metallic ink into separate components: metallic powder is applied as a dry layer or suspension rather than being jetted through nozzles. The binding resin is jetted separately to form adhesive layers that hold the metallic powder, eliminating clogging while maintaining the metallic appearance effect
Solution Approach 2:
The patent introduces a binding resin as an intermediary substance that attaches metallic powder to the substrate. This mediator allows the metallic powder to be applied without requiring it to pass through inkjet nozzles, thus preventing clogging while still achieving the desired metallic decoration
2Shape
If UV-curable metallic ink with metal flake pigment is used, then metallic appearance is achieved, but oxidation of metal flake occurs over time causing loss of shine
Solution Approach 1:
The patent applies clear coat layers (protective resins) over the metallic powder to create a protective environment that shields the metal flake from oxygen exposure. This inert barrier prevents oxidation while preserving the metallic shine and appearance over time
Solution Approach 2:
The patent creates a composite structure combining metallic powder, binding resin, and protective clear coat layers. This multi-layer composite material provides both the desired metallic appearance and protection against oxidation, as the clear coat acts as a barrier layer
3Shape
If multiple layers of UV-curable resin and metallic material are layered to achieve deep three-dimensional metallic appearance, then the aesthetic effect is improved, but the manufacturing process becomes more complex and costly
Solution Approach 1:
The patent combines multiple functions into fewer processing steps: the binding resin layer serves both as an adhesive for metallic powder and as a base for subsequent layers, while UV curing is applied uniformly across all layers. This merging of functions simplifies the overall process compared to traditional multi-step metallic printing methods
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach effectively achieves a deep, three-dimensional, and metallic appearance at a lower cost by ensuring that multiple metallic layers are visible, enhancing the aesthetic without the drawbacks of UV-curable metallic ink, such as nozzle clogging and oxidation.
Implementation Method 1
ink-jet printing using an ultraviolet (UV) curable resin (e.g., an UV ink), which cures upon irradiation with UV rays
Data Source
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AI summary
Sports equipment in accordance with one aspect of the invention has a base member 10 and a decorative layer(s) 20. The decorative layer 20 comprises a first adhesive layer 22A of ultraviolet-curable resin formed into a first decorative shape by ink-jet printing, a first metallic material layer 24A adhered on the first adhesive layer 22A the first metallic material layer being formed into the first decorative shape, a second adhesive layer 22B of ultraviolet-curable resin disposed on the upper side of the first metallic material layer 24A by ink-jet printing, the second adhesive layer being formed into a second decorative shape and a second metallic material layer 24B adhered on the second adhesive layer 22B the second metallic material layer being formed into the second decorative shape, wherein the first metallic material layer 24A is exposed or visible through gaps of each dots of the ultraviolet-curable resin which forms the second adhesive layer 22B.